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March 16, 2022 NHTSA CAMPAIGN NUMBER: 22V160000
Brake Fluid Warning Labels May Detach/FMVSS 122
Missing brake fluid warning labels may lead to improper brake system maintenance, affecting brake performance and increasing the risk of a crash.
NHTSA Campaign Number: 22V160
Manufacturer Harley-Davidson Motor Company
Components SERVICE BRAKES, HYDRAULIC, EQUIPMENT
Potential Number of Units Affected 4,177
Summary
Harley-Davidson Motor Company (Harley-Davidson
) is recalling certain 2021-2022 XL1200X, XL883N, and 2021 XL1200NS XL Sportster motorcycles. The brake fluid
warning labels may detach from the brake fluid
reservoir caps. As such, these motorcycles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 122, “Motorcycle Brake Systems.”
Remedy
Harley-Davidson will mail replacement labels to owners, free of charge. Owners may also take their motorcycles to a dealer for label inspection and replacement, free of charge. Owner notification letters were mailed April 4, 2022. Harley’s number for this recall is 0632.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Check for Harley-Davidson Recalls
Supplemental Procedure Video
WARNING
Always review the appropriate service procedure prior to performing it. This video is intended to supplement, not replace, documented service procedures. Attempting service procedures without the proper training, tools, equipment, and manuals could result in death or injury to you or others. This could also damage the motorcycle or cause the motorcycle to operate improperly. (10406a)
This video is a supplement of the procedure covered in the document. This video can only be viewed through Service Information Portal (SIP).
https://serviceinfo.harley-davidson.com/sip/content/document/ view?id=1615454891662166318
Purpose for Service Bulletin
This bulletin informs dealers that Harley-Davidson has learned that certain 2021 and 2022 XL Sportster motorcycles may not be compliant with Federal Motor Vehicle Safety Standard (FMVSS) No. 122, Motorcycle Brake Systems. Due to a non-uniform edge, the brake fluid
warning decal(s) may not be adequately affixed to the front and rear brake master cylinder cover.
Motorcycles Affected
2021 and 2022 Sportster XL models.
Inspect
1. Try to remove the decal from front and rear brake master cylinder fluid cover with a finger nail.
2. If the decal cannot be removed with a finger nail, no further action is required.
Failure
1. If the decal begins to lift from the front or rear master cylinder cover, completely remove the decal.
NOTE
- Do not clean with denatured alcohol, mineral spirits or other solvents. Damage to components may occur.
- For maximum bond, surface must be clean and dry.
2. Ensure that surface is clean and dry.
Install Decal
NOTE
- Apply in ambient temperatures between 21โ38 ยฐC (70โ100 ยฐF).
- Parts cannot be repositioned after initial installation. Do not remove protective film from adhesive until ready to apply.
- Do not bend emblem to fit contour of mounting surface.
- Allow at least 24 hours after application before exposing the area to vigorous washing, strong water spray or extreme weather.
- The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.
1. Remove protective film from back of decal.
NOTE
2. Position decal in center of master cylinder fluid cover relief.
3. Apply even pressure across entire surface. Hold in place for 15 seconds.
4. Wait 20 minutes before touching decal.
5. If needed, repeat steps 1-4 for other master cylinder fluid cover relief.
Chronology :
02/03/2022 – Harley-Davidsonโs Technical Subcommittee (TSC) was made aware of a potential issue with MY22 XL (all models) built at York Vehicle Operations. An audit performed on 01/28/2022 revealed that the brake fluid
warning decal, part number 44791-07 (DECAL, FRT MSTR CYL/DOT 4), was missing from the front brake master cylinder cap on one of the vehicles inspected during the audit.
02/03/2022 – 02/28/2022 – The TSC conducted a root cause and scope analysis. This included an audit of vehicles as well as discussions with the supplier. The TSCโs investigation indicated that due to a non-uniform edge on the decal, the brake fluid warning statement on some of these vehicles may not be permanently affixed.
03/03/2022 โ The Field Action Committee (FAC) reviewed the TSCโs findings and analysis and escalated the matter to H-Dโs Executive Decision Authority (EDA).
03/08/2022 โ Based upon the information developed during the investigation, the EDA determined that this condition may constitute a noncompliance with FMVSS 122, S5.1.9, and authorized a recall to address this condition. There have been no reports of any accidents or injuries related to this issue.
5 Affected Products
Vehicles
MAKE | MODEL | YEAR |
HARLEY-DAVIDSON![]() | XL1200NS | 2021 |
HARLEY-DAVIDSON![]() | XL1200X | 2021-2022 |
HARLEY-DAVIDSON![]() | XL883N | 2021-2022 |
8 Associated Documents
Noncompliance Notice 573 Report
RCLRPT-22V160-3532.PDF 217.992KB
Recall Acknowledgement
RCAK-22V160-1787.pdf 645.505KB
Recall 573 Report – March 24, 2022
RCLRPT-22V160-8153.PDF 218.05KB
Remedy Instructions and TSB
RCRIT-22V160-7447.pdf 125.805KB
Manufacturer Notices(to Dealers,etc)
RCMN-22V160-3359.pdf 118.411KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V160-3233.pdf 301.768KB
Recall Quarterly Report #1, 2022-2
RCLQRT-22V160-4901.PDF 211.152KB
Recall Quarterly Report #3, 2022-4
RCLQRT-22V160-2148.PDF 211.333KB
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V160&docType=RCL
- Provides an extra margin of safety in extreme braking conditions
- Mix of polyglycol ethers ensures hot brake-system operation will not create dangerous vapor
- Excellent for ABS
, disc and drum brake systems
- Delivers braking power when needed by avoiding a spongy pedal
- Both wet and dry boiling points exceed the minimum government standards
- High compatibility. Use with or direct replacement for DOT 3, DOT 4, and DOT 5. 1
- Extended Service Interval (ESI): Lasts 100 percent longer than DOT 3, 50 percent longer than DOT 4, and 10 percent longer than DOT 5. 1
- Exceeds all DOT 3, DOT 4, and DOT 5. 1 standards
- Wet boiling point ~ 365 DegreeF/Viscosity at -40 DegreeC ~ 685mm2/s
- Standard brake fluid
has a recommended change interval of 2 years. The recommended change interval for Bosch
ESI6 is 3 years.
- The 336โฐF wet boil point and 521โฐF dry boil point exceeds common characteristics for DOT 4 brake fluids
- Provides corrosion protection in brake components
- Matches needs of all DOT 4 manufacturer recommendations
- Compatible with all DOT 3 and DOT 4 applications
- Helps provide protection against brake failure from vapor lock
- Helps prevent corrosion in brake system
- Works with all brake system requiring DOT 3 fluids
- Exceeds federal motor vehicle safety standard No. 116
- Meets SAE spec. J1703.
- Premium DOT 3 Brake Fluid
has a minimum boiling point of 450ยฐF
- Meets and exceeds DOT 3 and all other Federal and SAE specifications and standards for motor vehicle brake fluids
- Mixes with all DOT 3 approved brake fluids
- Designed for use in disc, drum and ABS
brake systems
- Premium brake and hydraulic clutch fluid that protects internal components from corrosion under normal use
- High boiling point to minimize brake fluid
boiling and vapor lock
- Excellent low temperature capability and stability when used where lower cold viscosities are required
- Excellent low temperature capability and stability when used where lower cold viscosities are required
- Synthetic quality brake fluid
- Contains special ingredients to guard against vapor lock and moisture absorption
- Exceeds requirements for both DOT 3 and DOT 4 brake fluids
- Specially formulated for DOT 4 brake fluid applications
- Designed for use in disc, drum and ABS
brake systems
- Maintains proper movement for safe, effective stopping performance
- Helps deliver a quieter braking system
- Produces smoother pedal travel
- Provides longer brake life and performance
- Install Wagner with total confidence
- An exclusive European formula with an exceptionally high boiling point and superior anti-vapor lock characteristics
- Superior braking during arduous conditions like racing and rallying
- Typical wet boiling point is 270deg. C
SEOCONTENT-START
IMPORTANT RECALL INFORMATION Regulatory Non-Compliance Recall Campaign 0632 MY21 and MY22 XL Sportster Brake Master Cylinder DOT4 Decal To: US and Canadian Dealers Roles: Dealer Operator, General Manager, All P&A Roles, All Service Roles, Vehicle Sales Manager March 22, 2022 Dear Valued Harley-Davidson Dealer: Harley-Davidson
has learned that certain 2021 and 2022 XL Sportster motorcycles may not conform to the requirements of Federal and Canadian Motor Vehicle Safety Standard (FMVSS/CMVSS) No. 122, Motorcycle Brake Systems. Due to a non-uniform edge, the brake fluid
warning decal(s) on vehicles within the affected production range may not be permanently affixed to the front and/or rear brake master cylinder cap. A missing decal may lead to improper maintenance if the ownersโ manual (which also lists the brake fluid
type) is not available or consulted. We have voluntarily declared that this condition constitutes a regulatory non-compliance to allow us to formally recall (Campaign 0632) all affected motorcycles. The remedy is to first confirm if any motorcycles in your possession are covered by this recall. If covered, perform the recommended recall update per Service Bulletin M1551 (the โBulletinโ) to inspect and, if needed, replace the brake fluid
warning decal(s). The Bulletin outlines the repair and credit procedures for the recall update and additional relevant information. In accordance with federal regulations administered by the National Highway Traffic Safety Administration (NHTSA) and other appropriate market-specific government agencies, Harley- Davidson or authorized Harley-Davidson
dealers will provide notice to all owners of record of affected products with direction to arrange for the recall service. New decals will be mailed to current owners to install, if needed, and any motorcycles still in a dealerโs inventory will also receive a separate letter addressed to the dealership containing the replacement decals required. Alternatively, owners have been given the option to bring their motorcycles to a Harley- Davidson dealer service department for inspection and, if needed, decal installation. As required by federal law, you may sell but not deliver any affected motorcycles until the recall remedy is complete. Please refer to H-Dnet / My Toolbox / Warranty Campaign Center. Select โSafety Campaign Open VIN list,โ then select โ0632โ Campaign to view the VIN list. If you have any questions related to this recall, you can contact us at: โข U.S. dealers: Call 800-664-7762 and select the appropriate prompts โข International
dealers: Contact their regional office We take pride in the quality standards and controls we employ in our drive to lead the industry and deliver the world’s most desirable motorcycles. Thank you for your cooperation. Sincerely, Harley-Davidson
Motor Company, Inc. Recall 0632 Harley-Davidson
models covered by this recall: Model Year Model Build Date Range 2021-2022 XL1200X 08/23/21 โ 02/03/22 2021-2022 XL883N 08/23/21 โ 01/31/22 2021 XL1200NS 08/23/21 โ 10/21/21 Key Dates: โข On or about 03/22/2022: Service Bulletin posts โข On or about 04/04/2022: Owner notification letters begin mailing
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M1551 2022-03-22 M1551: RECALL 0632 – REGULATORY NON-COMPLIANCE 2021-2022 XL SPORTSTER BRAKE FLUID WARNING DECALS Supplemental Procedure Video WARNING Always review the appropriate service procedure prior to performing it. This video is intended to supplement, not replace, documented service procedures. Attempting service procedures without the proper training, tools, equipment, and manuals could result in death or injury to you or others. This could also damage the motorcycle or cause the motorcycle to operate improperly. (10406a) This video is a supplement of the procedure covered in the document. This video can only be viewed through Service Information Portal (SIP). https://serviceinfo.harley-davidson.com/sip/content/document/ view?id=1615454891662166318 Table 1. Video Links Video Link BRAKE FLUID
WARNING DECALS QR Code Reason for Revision Refer to Table 2. Table 2. Document History Date Revision Description 2022-03-22 Initial release Purpose for Service Bulletin This bulletin informs dealers that Harley-Davidson
has learned that certain 2021 and 2022 XL Sportster motorcycles may not be compliant with Federal Motor Vehicle Safety Standard (FMVSS) No. 122, Motorcycle Brake Systems. Due to a non-uniform edge, the brake fluid
warning decal(s) may not be adequately affixed to the front and rear brake master cylinder cover. Motorcycles Affected 2021 and 2022 Sportster XL models. Markets Affected United States, Canada and Puerto Rico. Required Dealer Action Table 3. Action Resolution Required Actionable: Any vehicle, component or software related issues must be performed per service bulletin procedure. NO YES Inspect 1. Try to remove the decal from front and rear brake master cylinder fluid cover with a finger nail. 2. If the decal cannot be removed with a finger nail, no further action is required. Failure 1. If the decal begins to lift from the front or rear master cylinder cover, completely remove the decal. NOTE โข Do not clean with denatured alcohol, mineral spirits or other solvents. Damage to components may occur. NOTE In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your dealership for either maintenance or service. LEADTECHNICIAN TECHNICIAN NO. 1 TECHNICIAN NO. 2 TECHNICIAN NO. 3 RETURN THIS TO WARRANTY PROCESS MANAGER SERVICE SALES MANAGER PARTS MANAGER ROUTING MANAGER INITIAL HERE โข For maximum bond, surface must be clean and dry. 2. Ensure that surface is clean and dry. Install Decal NOTE โข Apply in ambient temperatures between 21โ38 ยฐC (70โ100 ยฐF). โข Parts cannot be repositioned after initial installation. Do not remove protective film from adhesive until ready to apply. โข Do not bend emblem to fit contour of mounting surface. โข Allow at least 24 hours after application before exposing the area to vigorous washing, strong water spray or extreme weather. โข The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature. 1. Remove protective film from back of decal. NOTE โข Protect adhesive from grease, oil, dust, dirt and fingerprints. โข Once applied, do not shift decal. 2. Position decal in center of master cylinder fluid cover relief. 3. Apply even pressure across entire surface. Hold in place for 15 seconds. 4. Wait 20 minutes before touching decal. 5. If needed, repeat steps 1-4 for other master cylinder fluid cover relief. Credit Procedure NOTE Enter bulletin number into comment section of claim. For each vehicle involved in this recall (involvement of Vehicle Identification Number (VIN) has been verified on h-dnet.com), submit a recall claim per Table 4. Table 4. ITEM DATA Claim Type SRC Problem Part Number 44791-07 Quantity Leave Blank Primary Labor Code 2719 (1) Time 0.2 h Customer Concern Code 0632 Condition Code 9981 (1) Download may be required Upon submission of the properly completed claim, you will be credited for 0.2 hours of labor time for performing the procedure, plus appropriate administrative time. Submit campaign events on their own warranty claim. Do not mix them with other warranty events. 2 / 2 M1551
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Harley-Davidson Motor Company, 3700 West Juneau Ave., PO Box 653, Milwaukee, WI 53201 414/342-4680 IMPORTANT SAFETY RECALL This notice applies to your vehicle, VIN # 1HD4LE211NB April 4th, 2022 Harley-Davidson
Recall No. 0632 NHTSA Recall No. 22V-160 Dear Harley-Davidson
Motorcycle Owner: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Harley-Davidson
Motor Company, Inc. has decided that certain 2021 and 2022 XL Sportster motorcycles may fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) No. 122, Motorcycle Brake Systems. We are notifying you because our records indicate that you may own one of these motorcycles. What is the Issue? The brake fluid
warning decal(s), which identifies the correct brake fluid
type for your motorcycle (i.e., DOT 4), may detach from the front and/or rear brake master cylinder cap. A missing decal may lead to improper brake system maintenance, which could, over time, affect brake system performance and increase the risk of a crash. Note: Your ownerโs manual also lists the brake fluid
type appropriate for your vehicle and should be consulted. What Should You Do? The enclosed instruction sheet provides instructions for inspecting your motorcycle to determine whether the recall condition is present. If one or both of the brake fluid
warning decals is loose, follow the instructions to replace the decal using one of the decals supplied with this letter. Alternatively, you may contact your authorized Harley-Davidson
dealer to schedule an appointment to have the decals inspected and replaced. The repair will be performed at no cost to you and should take less than a half hour. However, due to scheduling, the dealer may require your motorcycle for a longer period. Once the service has been completed, your dealer will ask you to sign a recall claim. DFFDDADFAADTDTATFAAFATTTTDAFDFAADTDFFFAFAFAFTDDATDTTAFDDAATDTTDFD *************AUTO**ALL FOR AADC 530 P1 C1 ## 0632 If you have sold your motorcycle and have an address for the current owner, it is important that you forward this notice to the new owner. Alternatively, you may contact us at the Harley- Davidson phone numbers listed below and provide us with the new contact information so that we may notify the new owner of this recall. Also, federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten (10) days. What If You Have Additional Questions or Concerns? For more information, or if you take your motorcycle to your dealer on a mutually agreed upon date and they are unable to perform the required service to your satisfaction, please contact Harley-Davidson
Motor Company, Inc. at 1-800-258-2464 in the U.S. or 1-414-343-4056 world-wide. If you are still having difficulty getting your vehicle serviced in a reasonable time or without charge, you may write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590; or call the toll-free Auto Safety Hotline at 1-888-327-4236 (TTY:1-800-424-9153); or go to https://www.safercar.gov. We regret any inconvenience this may cause you, but we are initiating this action in the interest of your satisfaction with our products. Thank you for your cooperation. Sincerely, Harley-Davidson
Motor Company, Inc. Recall 0632 M1551_Customer Letter 2022-04-04 M1551: RECALL 0632 – REGULATORY NON-COMPLIANCE 2021-2022 XL SPORTSTER BRAKE FLUID
WARNING DECALS Supplemental Procedure Video WARNING Always review the appropriate service procedure prior to performing it. This video is intended to supplement, not replace, documented service procedures. Attempting service procedures without the proper training, tools, equipment, and manuals could result in death or injury to you or others. This could also damage the motorcycle or cause the motorcycle to operate improperly. (10406a) This video is a supplement of the procedure covered in the document. This video can only be viewed through Service Information Portal (SIP). https://serviceinfo.harley-davidson.com/sip/content/document/ view?id=1615454891662166318 Table 1. Video Links Video Link BRAKE FLUID
WARNING DECALS QR Code Reason for Revision Refer to Table 2. Table 2. Document History Date Revision Description Removed Table 3. Reworded section header 2022-04-04 (ID5). 2022-03-22 Initial release Purpose for Service Bulletin This bulletin informs dealers that Harley-Davidson
has learned that certain 2021 and 2022 XL Sportster motorcycles may not be compliant with Federal Motor Vehicle Safety Standard (FMVSS) No. 122, Motorcycle Brake Systems. Due to a non-uniform edge, the brake fluid
warning decal(s) may not be adequately affixed to the front and rear brake master cylinder cover. Motorcycles Affected 2021 and 2022 Sportster XL models. Markets Affected United States, Canada and Puerto Rico. Required Customer or Dealer Action Inspect 1. Try to remove the decal from front and rear brake master cylinder fluid cover with a finger nail. 2. If the decal cannot be removed with a finger nail, no further action is required. Failure 1. If the decal begins to lift from the front or rear master cylinder cover, completely remove the decal. NOTE โข Do not clean with denatured alcohol, mineral spirits or other solvents. Damage to components may occur. โข For maximum bond, surface must be clean and dry. 2. Ensure that surface is clean and dry. Install Decal NOTE โข Apply in ambient temperatures between 21โ38 ยฐC (70โ100 ยฐF). โข Parts cannot be repositioned after initial installation. Do not remove protective film from adhesive until ready to apply. โข Do not bend emblem to fit contour of mounting surface. โข Allow at least 24 hours after application before exposing the area to vigorous washing, strong water spray or extreme weather. โข The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature. 1. Remove protective film from back of decal. NOTE โข Protect adhesive from grease, oil, dust, dirt and fingerprints. โข Once applied, do not shift decal. 2. Position decal in center of master cylinder fluid cover relief. 3. Apply even pressure across entire surface. Hold in place for 15 seconds. 4. Wait 20 minutes before touching decal. 5. If needed, repeat steps 1-4 for other master cylinder fluid cover relief. 2 / 2 M1551_Customer Letter
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-160 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Harley-Davidson Motor Company Submission Date : MAR 24, 2022 NHTSA Recall No. : 22V-160 Manufacturer Recall No. : 0632 Manufacturer Information : Manufacturer Name : Harley-Davidson
Motor Company Address : 3700 W. Juneau Avenue Milwaukee WI 53201-0653 Company phone : (414) 343-4056 Population : Number of potentially involved : 4,177 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2021-2022 Harley-Davidson
XL1200X Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The Brake Master Cylinder DOT4 Decal (P/N 44791-07) on certain 2021 and 2022 XL Sportster motorcycles may not be permanently affixed. Number of affected vehicles: 416 XL1200X motorcycles for the 2021 model year and 725 XL1200X motorcycles for the 2022 model year. Motorcycles which were within Harley-Davidson
โs control on 02/03/2022, as well as those produced after these build date ranges, have either received updated parts or have been verified to not contain the recall condition. Production Dates : AUG 23, 2021 – FEB 03, 2022 VIN Range 1 : Begin : 1HD1LC32XMB417502 End : 1HD1LC311NB403786 โ Not sequential Vehicle 2 : 2021-2022 Harley-Davidson
XL883N Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The Brake Master Cylinder DOT4 Decal (P/N 44791-07) on certain 2021 and 2022 XL Sportster motorcycles may not be permanently affixed. Number of affected vehicles: 1233 XL883N motorcycles for the 2021 model year and 1635 XL883N motorcycles for the 2022 model year. Motorcycles which were within Harley-Davidson
โs control on 02/03/2022, as well as those produced after these build date ranges, have either received updated parts or have been verified to not contain the recall condition. Production Dates : AUG 23, 2021 – JAN 31, 2022 VIN Range 1 : Begin : 1HD4LE211MB417499 End : 1HD4LE212NB403631 โ Not sequential Part 573 Safety Recall Report 22V-160 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 Vehicle 3 : 2021-2021 Harley-Davidson
XL1200NS Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The Brake Master Cylinder DOT4 Decal (P/N 44791-07) on certain 2021 and 2022 XL Sportster motorcycles may not be permanently affixed. Number of affected vehicles: 168 XL1200NS motorcycles for the 2021 model year. Motorcycles which were within Harley-Davidsonโs control on 02/03/2022, as well as those produced after these build date ranges, have either received updated parts or have been verified to not contain the recall condition. Production Dates : AUG 23, 2021 – OCT 21, 2021 VIN Range 1 : Begin : 1HD1LP318MB417500 End : 1HD1LP316MB419567 โ Not sequential Description of Noncompliance : Description of the Noncompliance : Due to a manufacturing defect on the Brake Master Cylinder DOT4 Decal (P/N 44791-07), some vehicles in the target population may not be compliant with FMVSS 122, S5.1.9. Specifically, the brake fluid
warning statement on some of these vehicles may not be permanently affixed. FMVSS 1 : 122 – Motorcycle brake systems FMVSS 2 : NR Description of the Safety Risk : The absence of the brake fluid
warning statement on the reservoir cover may lead to an improper maintenance procedure if the owner does not have access to or does not consult the ownersโ manual (which contains the brake fluid
specifications). Improper brake system maintenance could, over time, affect brake system performance and increase the risk of a crash. Description of the Cause : Brake Master Cylinder DOT4 Decal (P/N 44791-07) may contain a non-uniform edge which may prevent the decal from permanently adhering to the cover surface. Identification of Any Warning that can Occur : An operator may notice a loose or out-of-position decal. Involved Components : Component Name 1 : CAP, FRT MSTR CYL/DOT4 Component Description : Cap, Front Master Cylinder Component Part Number : 42804-07 Part 573 Safety Recall Report 22V-160 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Component Name 2 : COVER, RR BRAKE MSTR CYL Component Description : Master Cylinder Cover Kit Rear Component Part Number : 41700095 Supplier Identification : Component Manufacturer Name : Hitachi Astemo, Ltd Address : 1901 Industrial Drive Findlay Ohio 45840 Country : United States Chronology : 02/03/2022 – Harley-Davidsonโs Technical Subcommittee (TSC) was made aware of a potential issue with MY22 XL (all models) built at York Vehicle Operations. An audit performed on 01/28/2022 revealed that the brake fluid
warning decal, part number 44791-07 (DECAL, FRT MSTR CYL/DOT 4), was missing from the front brake master cylinder cap on one of the vehicles inspected during the audit. 02/03/2022 – 02/28/2022 – The TSC conducted a root cause and scope analysis. This included an audit of vehicles as well as discussions with the supplier. The TSCโs investigation indicated that due to a non-uniform edge on the decal, the brake fluid
warning statement on some of these vehicles may not be permanently affixed. 03/03/2022 โ The Field Action Committee (FAC) reviewed the TSCโs findings and analysis and escalated the matter to H-Dโs Executive Decision Authority (EDA). 03/08/2022 โ Based upon the information developed during the investigation, the EDA determined that this condition may constitute a noncompliance with FMVSS 122, S5.1.9, and authorized a recall to address this condition. There have been no reports of any accidents or injuries related to this issue. Part 573 Safety Recall Report 22V-160 Page 4 The information contained in this report was submitted pursuant to 49 CFR ยง573 Description of Remedy : Description of Remedy Program : Replacement decals will be mailed to owners of affected motorcycles with instructions to inspect the decals on their motorcycle. Instructions on how to install replacement decals, if needed, will also be provided. Owners will also be given the option to arrange service with an authorized Harley- Davidson dealer, who will perform the remedy at no charge to the customer. Pursuant to 49 CFR 577.11(e), Harley-Davidson requests that it be exempt from providing a notification of a reimbursement plan. Any prenotification product failure would have been addressed under the manufacturerโs limited warranty. Accordingly, no person would be eligible for reimbursement pursuant to 573.13. How Remedy Component Differs from Recalled Component : The updated decals do not contain the manufacturing defect that causes this condition in the recalled vehicles. Identify How/When Recall Condition was Corrected in Production : Updated decals were introduced into production on approximately 02/08/2022. Recall Schedule : Description of Recall Schedule : Harley-Davidson will notify the dealer network between 03/21/2022 and 03/28/2022. Owner notification letters will be sent between 03/22/2022 and 03/29/2022. Planned Dealer Notification Date : MAR 21, 2022 – MAR 28, 2022 Planned Owner Notification Date : APR 01, 2022 – APR 08, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-160 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Harley-Davidson Motor Company Submission Date : MAR 16, 2022 NHTSA Recall No. : 22V-160 Manufacturer Recall No. : 0632 Manufacturer Information : Manufacturer Name : Harley-Davidson Motor Company Address : 3700 W. Juneau Avenue Milwaukee WI 53201-0653 Company phone : (414) 343-4056 Population : Number of potentially involved : 4,177 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2021-2022 Harley-Davidson XL1200X Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The Brake Master Cylinder DOT4 Decal (P/N 44791-07) on certain 2021 and 2022 XL Sportster motorcycles may not be permanently affixed. Number of affected vehicles: 416 XL1200X motorcycles for the 2021 model year and 725 XL1200X motorcycles for the 2022 model year. Motorcycles which were within Harley-Davidsonโs control on 02/03/2022, as well as those produced after these build date ranges, have either received updated parts or have been verified to not contain the recall condition. Production Dates : AUG 23, 2021 – FEB 03, 2022 VIN Range 1 : Begin : 1HD1LC32XMB417502 End : 1HD1LC311NB403786 โ Not sequential Vehicle 2 : 2021-2022 Harley-Davidson XL883N Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The Brake Master Cylinder DOT4 Decal (P/N 44791-07) on certain 2021 and 2022 XL Sportster motorcycles may not be permanently affixed. Number of affected vehicles: 1233 XL883N motorcycles for the 2021 model year and 1635 XL883N motorcycles for the 2022 model year. Motorcycles which were within Harley-Davidsonโs control on 02/03/2022, as well as those produced after these build date ranges, have either received updated parts or have been verified to not contain the recall condition. Production Dates : AUG 23, 2021 – JAN 31, 2022 VIN Range 1 : Begin : 1HD4LE211MB417499 End : 1HD4LE212NB403631 โ Not sequential Part 573 Safety Recall Report 22V-160 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 Vehicle 3 : 2021-2021 Harley-Davidson XL1200NS Vehicle Type : MOTORCYCLES Body Style : OTHER Power Train : GAS Descriptive Information : The Brake Master Cylinder DOT4 Decal (P/N 44791-07) on certain 2021 and 2022 XL Sportster motorcycles may not be permanently affixed. Number of affected vehicles: 168 XL1200NS motorcycles for the 2021 model year. Motorcycles which were within Harley-Davidsonโs control on 02/03/2022, as well as those produced after these build date ranges, have either received updated parts or have been verified to not contain the recall condition. Production Dates : AUG 23, 2021 – OCT 21, 2021 VIN Range 1 : Begin : 1HD1LP318MB417500 End : 1HD1LP316MB419567 โ Not sequential Description of Noncompliance : Description of the Noncompliance : Due to a manufacturing defect on the Brake Master Cylinder DOT4 Decal (P/N 44791-07), some vehicles in the target population may not be compliant with FMVSS 122, S5.1.9. Specifically, the brake fluid warning statement on some of these vehicles may not be permanently affixed. FMVSS 1 : 122 – Motorcycle brake systems FMVSS 2 : NR Description of the Safety Risk : The absence of the brake fluid warning statement on the reservoir cover may lead to an improper maintenance procedure if the owner does not have access to or does not consult the ownersโ manual (which contains the brake fluid specifications). Description of the Cause : Brake Master Cylinder DOT4 Decal (P/N 44791-07) may contain a non-uniform edge which may prevent the decal from permanently adhering to the cover surface. Identification of Any Warning that can Occur : An operator may notice a loose or out-of-position decal. Involved Components : Component Name 1 : CAP, FRT MSTR CYL/DOT4 Component Description : Cap, Front Master Cylinder Component Part Number : 42804-07 Part 573 Safety Recall Report 22V-160 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Component Name 2 : COVER, RR BRAKE MSTR CYL Component Description : Master Cylinder Cover Kit Rear Component Part Number : 41700095 Supplier Identification : Component Manufacturer Name : Hitachi Astemo, Ltd Address : 1901 Industrial Drive Findlay Ohio 45840 Country : United States Chronology : 02/03/2022 – Harley-Davidsonโs Technical Subcommittee (TSC) was made aware of a potential issue with MY22 XL (all models) built at York Vehicle Operations. An audit performed on 01/28/2022 revealed that the brake fluid warning decal, part number 44791-07 (DECAL, FRT MSTR CYL/DOT 4), was missing from the front brake master cylinder cap on one of the vehicles inspected during the audit. 02/03/2022 – 02/28/2022 – The TSC conducted a root cause and scope analysis. This included an audit of vehicles as well as discussions with the supplier. The TSCโs investigation indicated that due to a non-uniform edge on the decal, the brake fluid warning statement on some of these vehicles may not be permanently affixed. 03/03/2022 โ The Field Action Committee (FAC) reviewed the TSCโs findings and analysis and escalated the matter to H-Dโs Executive Decision Authority (EDA). 03/08/2022 โ Based upon the information developed during the investigation, the EDA determined that this condition may constitute a noncompliance with FMVSS 122, S5.1.9, and authorized a recall to address this condition. There have been no reports of any accidents or injuries related to this issue. Part 573 Safety Recall Report 22V-160 Page 4 The information contained in this report was submitted pursuant to 49 CFR ยง573 Description of Remedy : Description of Remedy Program : Replacement decals will be mailed to owners of affected motorcycles with instructions to inspect the decals on their motorcycle. Instructions on how to install replacement decals, if needed, will also be provided. Owners will also be given the option to arrange service with an authorized Harley- Davidson dealer, who will perform the remedy at no charge to the customer. Pursuant to 49 CFR 577.11(e), Harley-Davidson requests that it be exempt from providing a notification of a reimbursement plan. Any prenotification product failure would have been addressed under the manufacturerโs limited warranty. Accordingly, no person would be eligible for reimbursement pursuant to 573.13. How Remedy Component Differs from Recalled Component : The updated decals do not contain the manufacturing defect that causes this condition in the recalled vehicles. Identify How/When Recall Condition was Corrected in Production : Updated decals were introduced into production on approximately 02/08/2022. Recall Schedule : Description of Recall Schedule : Harley-Davidson will notify the dealer network between 03/21/2022 and 03/28/2022. Owner notification letters will be sent between 03/22/2022 and 03/29/2022. Planned Dealer Notification Date : MAR 21, 2022 – MAR 28, 2022 Planned Owner Notification Date : APR 01, 2022 – APR 08, 2022 * NR – Not Reported
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